Rotary cutters for sheet material



Nov. 28, 1967 P. LUC 3,354,768

ROTARY CUTTERS FOR SHEET MATERIAL Filed Oct. 20, 1965 2 Sheets-Sheet 1 IN VEN TOR. LEONARD P. Li/c/f Y M M A TTORNE) Nov. 28, 1967 1.. P. LIICK 3,354,768

ROTARY CUTTERS FOR SHEET MATERIAL Filed Oct. 20, 1965 2 Sheets-Sheet 2 Fi s.

A 50mm L flak W M M ATTORNEY United States Patent 3,354,768 ROTARY CUTTERS FOR SHEET MATERIAL Leonard P. Liick, 48 Mountainview Road, Trenton, NJ. @8628 Filed Oct. 20, 1965, Ser. No. 498,593 Claims. (Cl. 83-345) ABSTRACT OF THE DISCLOSURE Rotary cutters for sheet material wherein there is a punch carried by one rotary member and a complemenand die upon rotation of the rotary members by which .1

they are carried.

This invention relates to rotary cutters for use on sheet material and is directed primarily to means for forming curved or rounded cuts in the sheet material as for example when producing cards having rounded corners.

The cards which are used in data processing equipment must be accurately made and \formed without ragged edges or corners. More recently, such cards have been formed with rounded corners but considerable trouble has "been encountered in forming such rounded corners accurately and rapidly with the rotary cutters of the prior art. This has been due in part at least to the use of fixed die and punch elements which quite literally punch out curved or arcuate portions from the sheet. Moreover, the punch and die when thus employed have generally been made of materials which differ considerably in hardness in order to reduce the breakage resulting from continuous and high speed usage. The tendency for a relatively soft die or ,punch to wear rapidly in use has also made it necessary to adjust or replace these elements frequently with the result that much operating time is lost in maintaining the equipment in proper working condition.

In accordance with the present invention, a new type of die and punch assembly for use on rotary elements of a sheet cutting machine are provided whereby high speed and accurate, clean and fuzz-free cutting of sheets can be effected. The equipment is in particular adapted for use in producing data processing cards, such as IBM cards" which have rounded corners.

These results and advantages are preferably attained by providing one or more punches which may be mounted on one rotary element and cooperating and mating die or dies adapted to be mounted on another rotary element, wherein the die and punch are both made of relatively hard cutting material which have an extended useful life. These elements preferably are so formed and arranged as to afford a scissors-like, shearing action therebetween by reason of a yielding, relatively angular engagement of the cutting edges of the punch and die as they move relative to each other. The parts are further constructed and assembled with the rotary members so as to be readily accessible and easily adjusted to assure proper mating and engagement of the die and punch.

Accordingly, the principal objects of he present inven' tion are to increase the speed and accuracy with which sheet material may be severed along one or more arcuately extending lines, as for example, when producing cards having rounded corners; to reduce the cost of producing ice articles presenting curved or arcuately cut edges; to decrease the time and cost involved in adjusting or replacing the elements of a rotary cutter by which arcuate cuts may be made in sheet material; to increase the useful life of the dies and punches employed in producing cards or the like having rounded corners; and to provide rotary cutting machines With dies and punches which cooperate to exert a scissors-like action on the sheet material by reason of the yielding coaction thereof so as to produce clean, fuzzfree, rounded corners on cards or the like.

These and other objects and features of the present invention will be apparent from the following description thereof wherein reference is made to the figures of the accompanying drawings.

In the drawings:

FIG. 1 is a perspective illustrating a typical form of rotary cutter embodying the present invention and adapted for use in producing data processing cards.

FIG. 2 is an enlarged perspective illustrating the form of die employed as an element of the rotary cutter of FIG. 1;

FIG. 3 is a longitudinal sectional view through the die and a portion of the rotary cutter illustrated in FIG. 1 on the line 33 of FIG. 4.

FIG. 4 is an enlarged radial view of a pair of dies and associated elements employed in the assembly of FIG. 1; and

FIG. 5 is a perspective illustrating the punch employed in the assembly of FIG. 1. s

In that form of the invention chosen for purposes of illustration in the figures of the drawings, the equipment is designed for producing those cuts in a continuous strip or sheet of material which will serve to form the rounded edges of data processing cards produced from the sheet. The equipment utilized for this purpose preferably includes a pair of die assemblies 2 carried by a cylindrical rotary member or spool 4 and a pair of cooperating punches 6 carried by a cylindrical rotary member 8. The members 4 and 8 are rotated in opposite directions as indicated by the arrows in FIG. 1 to receive a sheet or strip of material 10 therebetween in which the arcuate or corner forming cuts 12 are to be formed. The members 4 and 8 are rotated at the same speed by suitable drive means such a's a gear (not shown) which meshes with one of the gears 16 on the ends of the members 4 and 8. The strip of material 10 is thus passed between the members 4 and 8 and is engaged by the elements of the die assembly 2 mounted on the member 4 and the punch 6 mounted on the'member 8 to form the rounded corner cuts 12 on adjacent connected cards in the strip 10 at the opposite edges of the strip. The strip thus cut is passed on to a card-severing cutter (not shown) which serves to cut the strip 10 into individual round cornered cards along the line 18 indicated in FIG. 1.

In accordance with the present invention, the die assembly includes a right-hand die 20 and a left-hand die 22 which are positioned on opposite sides of the tongue 24 of an anvil or die positioning member 26. Each of the dies 20 and 22 is generally cylindrical in shape and preferably is cup-shaped in form so as to have a base 28 with an upwardly projecting cutting side portion 30 with an arcuate cutting edge 32 at the upper extremity thereof. A slot 34 is formed in the die at one side of the cutting portion 30 and extends downwardly toward the base 28 to permit limited radial movement of the cutting portion and its cutting edge 32 with respect to the adjacent side portion 36 of the die. One or more additional slots 38 may be formed in the side portion 36 of the die to decrease the stiffness thereof and avoid distortion of the cutting edge 32 of the cutting side portion 30 upon flexing thereof. v

Each die is further provided with an insert 40 formed of nylon or other material which is somewhat compressible and an O-ring 44 is located in an annular groove in the insert between the insert and the side portions 39 and 36 of the die. The die, insert and O-ring are cut away at 45, to provide a die locating edge 46 at one side of the cutting side portion 30 of the die. The die locating edges 46 of both of the dies 20 and 22 are positioned in side by side relation and in abutting engagement with the end of the tongue 24 of the anvil 26 so as to be accurately positioned with respect to each other and with respect to the rotary member 4 by which they are carried.

The dies are each secured in place by a flat headed adjusting and positioning screw 48 which passes through the insert 40 and into the surface 50 of a cavity 52 in which the dies and anvil are located. The cavity 52 is of such depth that the upper cutting edge 32 of the cutting side portion of the die will be substantially flush with the outer cylindrical surface of the rotary member 4. Furthermore, the cavity 52. is extended beyond the cutting side portions 30' of the dies to, provide a chip receiving passage 54 into which the punch 6 may project into operative engagement with the cutting side portions of the dies for severing the strip 10. The chips 56 which are severed from the strip. are drawn down into the chip receiving: passage 54. by suction applied to. a tube 58 connected axially to the rotary member 4 whereby they are removed from the dies and punch.

The sides, of the cavity 52 present rounded die locating surfaces 60 which cooperate with the rounded surfaces 62 onthe opposite sides of the tongue 24 of the anvil 26 to position the dies 20" and 22 accurately within the cavity 52 by engagement with the side portions 36 of the dies. Howeverjthe cutting side portions 30 of the dies face the .chip receiving passage 54 so that the outer faces thereof are exposed and unsupported to permit free passage of the severed chips downward from the cutting edge 32 to the passage 54 and to permit limited outward flexing of the side portion 30 to an. adjusted position upon compression of the insert 40 by the adjusting and positioning screw 48.

The punch 6 is located within a cavity 64 in the rotary member 8 and is secured in an adjusted position in the cavity by'a flat headed screw 66 which passes through an elongated slot 68 in the body 70 of the punch. The

punch is formed with a head 72 which projects radially from the adjacent surface of the rotary member 8 and is provided with concave arcuate cutting edges 74 and 76 designed for mating and sheet cutting coaction with the cutting edges 32 of' the. side portions 30 of the dies 20 and 22 respectively.

The punch and dies are preferably so positioned with respect to each other and with respect to the strip 10 of the material to be cut, that the initial mating engagement of the cutting edge 74 of the punch with the cutting edge 32 of the cutting side portion 30 of the die 20, will take place just beyond the edge 77 and. the strip 10 where the arcuate cut is to be made. Thereafter, upon continued rotary movement of the members 4 and 8, the cutting edges 74 and 32 of the punch and die 20 will cooperate to form an inwardly and arcuately extending cut in the strip so as to form one rounded corner of one of the cards to be later severed from the strip. Further, as the members 4 and 8 continue to rotate the cutting edge 76 of the punch 6 comes into mating engagement with the cutting edge 32 of the side portion 30 of die 22. and cooperates therewith to form an outwardly extending arcuate cut in the edge of the strip 10 to form the rounded corner of an adjacent card to be severed from the strip. The chip 56 is thus cut and completely severed from the edge of the strip so as to be free to be drawn into the chip receiving passage 54 and removed from the punch and die. The chips severed from the strip therefore do not fly aboutor interfere in any way with the operation of the punch and die in forming a further cut in the edge of the strip as the rotary members 4 and 8 continue to rotate.

During the cooperating action of the punch and die, the surfaces 74 and 76 are inclined relative to each other at an angle determined by the diameter of the rotary members 4 and 8. They therefore serve to cut the strip 10 with a scissors-like action between the cutting edges of the punch and dies so as to assure the formation of smooth, clean, fuzz-free, rounded corners on the cards preparatory to separation of the cards by transverse cutting of the strip along the line 18. Furthermore, the construction provided is such that the cutting side portions 30 of each die are yieldable inwardly to a limited extent against the action of the compressible O-ring 44 when engaged by the punch whereby interference and chipping or damaging of the cutting edges of the die and punch does not occur. As a result, it is possible to form both the dies and the punch of hard metals such as tool steel or the like which are capable of use at high speed and for long periods of time without injury or resharpening thereof. Moreover, the compressible insert 40 and the O-ring 42 can be subjected to suitable pressure under action. of the screw 48 to exert a controlled outwardly directed force against the inner surface of the cutting side portions 30 of each die. In this way, the positions of the cutting edges 32 of the dies can be accurately adjusted to assure the most effective mating and cutting action between the cutting edges 74 and 76 of the punch 6 and the cutting edges 32 of the dies.

in order further to provide for limited yielding movement of the cutting edges 32 of the dies, the base 28 of the cup-shaped dies and the surfaces 50 of the cavity 52 against which the dies are held by the screw 48-, may be formed to permit limited b'od'il-y tilting of the dies within the cavity 52. Thus as shown in FIG. 3, the base 28 of the die may present a; hat surface whereas the surface 50 engaged thereby may be slightly convex. The screw 48' which passes through the insert 40 then passes on down-ward through an opening. 78 in the base 28 of the die and into the rotary member 4 at the crest or highpoint of the convex surface 50 engaged by the base 28. Sufficient clearance is provided between the screw 48' and the sides of the opening 78 in the base of the die to allow the die to be bodily tilted to a minor degree by reason of compression of the O-ring- 42. In this way, deflection of the cutting edge 32. and side portion 30 of the die with respect to the base 28' of the die upon engagement with the punch and sheet material may be reduced and the danger of interference between the cutting edges of the die and punch are precluded. Moreover, the limited tilting and movement of the dies and side portions 30 thereof serve to provide greater freedom of movement of the punch and dies into and out of engagement as they move through relatively inclined and arcuate paths during rotation of the rotary members 4 and 8. In this way, the danger of interlocking,

interference, excessive wear or damage to the cutting edges of the dies and punch are further reduced.

As shown most clearly in FIG. 1, when producing data processing cards, the rotary members 4 and 8 are pro vided with cooperating punch and die assemblies located near the opposite ends of the rotary members and in position to form the rounded corners of adjacent cards simultaneously on opposite edges of the strip 10. It will also be apparent that the rotary members may be provided with any desired number of punches and dies circumferentially spaced 2 sufiicient distance to form arcuate cuts in a sheet of material at any desired locations therein. The circumference of the rotary members, or either of them, may accordingly be equal to any desired multiple of the spaces between the cuts to be made in the strip or sheet of material being handled;

It will also be apparent that the radius, curvature or shape of the arcuate cutting edges of the dies may be varied and if desired, punches and dies of dilferent shape or diameter may be used and they may be located at any suitable points orr the rotary members as required for producing arcuate cuts in various types of sheet material and for producing widely varying products.

In view thereof it should be understood that the particular embodiment of the invention shown in the drawings is intended to be illustrative only and is not intended to limit the scope of the invention.

I claim:

1. A device for forming an arcuate cut in a sheet of material, comprising two rotary members between which the sheet of material to be cut is movable, a punch carried by one of said rotary members and presenting an arcuate cutting edge corresponding in shape to the cut to be formed in the sheet of material, and a die carried by the other of said rotary members, said die having a plurality of side portions, one of which presents an arcuate cutting edge complementary with said cutting edge of the punch, said cutting edge of said side portion of the die being yieldably movable with respect to the rotary member by which the die is carried, said punch and die being located on said rotary members in position to bring the cutting edges thereof into cooperative contact while in inclined relation with respect to each other to form an arcuate scissors-like cut in said sheet of material upon rotation of said rotary members.

2. A device as set forth in claim 1 wherein said die is cup-shaped in form and said side portion of the die is yieldable with respect to the remaining portions of the die to vary the position of the cutting edge of said side portion of the die.

3. A device as set forth in claim 1 wherein a compressible member is located Within the die and bears against the inner surface of said side portion, and means are provided for varying the pressure exerted on said side portion by said compressible member to vary the position of the cutting edge of said side portion of the die.

4. A device as set forth in claim 1 wherein said die is bodily tiltable with respect to the rotary member to vary the position of the cutting edge of said side portion of the die.

5. A device as set forth in claim 1 wherein the rotary member by which the die is carried presents a cylindrical surface with a recess therein and said die is located in said recess with the cutting edge of the side portion of the die positioned substantially flush with said surface of the rotary member.

6. A device as set forth in claim 5 wherein said side portion of the die is exposed in said recess and said punch is movable into and out of said recess and into and out of mating engagement with said side portion of said die to form an arcuate cut in said sheet of material.

7. A device for use in forming cards having rounded corners from a strip of material of predetermined width, comprising two rotary members presenting cylindrical surfaces between which the strip of material may be passed, one .of said rotary members having a punch carried thereby and projecting from the cylindrical surface thereof, said punch presenting two adjacent and oppositely extending curved cutting edges corresponding in shape to the rounded corners of two adjacent cards to be produced from the strip, the other rotary member having a cavity therein into which said punch may project upon rotation of said rotary members, two dies located side by side in said cavity each of which dies has a cutting side portion presenting an arcuate and radially movable cutting edge facing that portion of said cavity into which the punch may project, said side portion on one of said dies presenting said arcuate cutting edge in position to cooperate with one of the curved cutting edges of the punch to form a rounded corner of one of two adjacent cards to be formed from said strip, said arcuate cutting edge of the side portion of the other of said dies being positioned to cooperate with the other curved cutting edge of the punch to form the rounded corner of the other of two adjacent cards, and a die positioning member located in said cavity and engaged by a radially extending edge of the side portions of each of said dies to hold the dies in predetermined positions in said cavity.

8. A device as defined in claim 7 wherein said dies are cup-shaped in form and the cutting edges of said side portions of said dies are movable radially with respect to the remaining portions of said dies.

9. A device as defined in claim 7 wherein said dies are cup-shaped in form and compressible means are located within the dies in position to urge said side portions of said dies outwardly.

10. A device as defined in claim 7 wherein said dies are cup-shaped in form and each present a bottom surface which engages a surface on the bottom of the cavity in which it is located which is divergent outwardly from the center of the die to permit the die to be bodily tilted.

References Cited UNITED STATES PATENTS 1,206,754 11/1916 Duvall 83345 X 2,525,042 10/1950 Minarik 83406 X 3,165,959 l/l965 Eidson 83406 X JAMES M. MEISTER, Primary Examiner. 

1. A DEVICE FOR FORMING AN ARCUATE CUT IN A SHEET OF MATERIAL, COMPRISING TWO ROTARY MEMBERS BETWEEN WHICH THE SHEET OF MATERIAL TO BE CUT IS MOVABLE, A PUNCH CARRIED BY ONE OF SAID ROTARY MEMBERS AND PRESENTING AN ARCUATE CUTTING EDGE CORRESPONDING IN SHAPE TO THE CUT TO BE FORMED IN THE SHEET OF MATERIAL, AND A DIE CARRIED BY THE OTHER OF SAID ROTARY MEMBERS, SAID DIE HAVING A PLURALITY OF SIDE PORTIONS, ONE OF WHICH PRESENTS AN ARCUATE CUTTING EDGE COMPLEMENTARY WITH SAID CUTTING EDGE OF THE PUNCH, SAID CUTTING EDGE OF SAID SIDE PORTION OF THE DIE BEING YIELDABLY MOVABLE WITH RESPECT TO THE ROTARY MEMBER BY WHICH THE DIE IS CARRIED, SAID PUNCH AND DIE BEING LOCATED ON SAID ROTARY MEMBERS IN POSITION TO BRING THE CUTTING EDGES THEREOF INTO COOPERATIVE CONTACT WHILE IN INCLINED RELATION WITH RESPECT TO EACH OTHER TO FORM AN ARCUATE SCISSORS-LIKE CUT IN SAID SHEET OF MATERIAL UPON ROTATION OF SAID ROTARY MEMBERS. 